Nonwoven fabric and process for forming the same

ABSTRACT

The present invention relates to a nonwoven fabric comprising a plurality of polypropylene-containing fibers that form a nonwoven web, which fibers in addition contain a slip agent, the web has a side which is provided with an alternating pattern which consists of individualized bonded areas which bonded areas are in the form of rods which are arranged in the cross direction of the web, the alternating pattern of individualized bonded areas defines a non-bonded area, the web has a basis weight on the range of from 5-25 g/m2, the surface of the bonded areas is in the range of 5-20% of the total surface of the side, and the surface of the non-bonded area is in the range of 80-95% of the total surface of the side. The present invention further relates to a process for forming the nonwoven fabric.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/540,398, filed Jun. 28, 2017, which is a national stage application,filed under 35 U.S.C. § 371, of International Application No.PCT/EP2015/077422, filed Nov. 24, 2015, which claims priority toEuropean Application No. 1510009.7, filed Jan. 2, 2015, each of which isincorporated by reference herein by its entirety.

FIELD

The present invention relates to a nonwoven fabric and a process forforming the nonwoven fabric.

BACKGROUND OF THE INVENTION

Nonwoven fabrics are widely applied in disposable absorbent articles forpersonal care or hygiene. In such articles the appearance of softness isof great importance since it reassures the wearer or caregiver that thearticle will be experienced as comfortable.

In WO 2012/024576 A1, an absorbent article adapted to be worn about awearer's lower torso is described which aims to enhance the perceivedsoftness of the absorbent article. The absorbent article described insaid document comprises a liquid permeable top sheet, a liquidimpermeable back sheet and an absorbent core disposed between the topsheet and the back sheet. The liquid impermeable back sheet comprises alaminate of a wearer-facing layer of liquid impermeable, vapourpermeable polymeric film and a garment-facing layer of a nonwoven web.The nonwoven web is being impressed with a first pattern of bondimpressions in the shape of diamonds, which first pattern defines asecond pattern of unbounded raised regions which also have the shape ofdiamonds. In this respect reference is made to FIGS. 3A-4B. In theprocess for manufacturing the nonwoven web a hydroentangling orhydroengorgement process is required to increase loft and/or calliper,enhancing visual and tactile softness signals. A drawback of suchhydroentangling or hydroengorgement process is, however, that it addsconsiderably to the manufacturing costs of the absorbent articles.Moreover, the softness of said absorbent articles leaves room forimprovement.

WO 2006/048173 describes a loop-forming nonwoven material for amechanical closure system. The fabrics are thermally bonded with a firstpattern of bond impressions that create a second pattern of largerunbonded raised regions and a third pattern of smaller unbonded areas.The impressions are a combination of trilobally and linearly shapedgeometry. This provides a positive impact on the mechanical stability ofthe fabric but has the disadvantage that it limits the drapability, animportant feature for softness perceiveness.

Object of the present invention is to provide a nonwoven fabric suitablefor use in an absorbent article having a simplified pattern of bondedand non-bonded areas which can more easily be manufactured, and which atthe same time shows an improved softness.

It is a further object of the present invention to provide adimensionally stable nonwoven fabric with improved softness, sufficientshear strength, and a high tensile strength.

It is yet another object of the present invention to nonwoven fabricsthat can be used as wet and dry wipes.

SUMMARY OF THE INVENTION

It has now been found that this can be established when use is made of acombination of a particular pattern of bonded and non-bonded areas andpolypropylene-containing fibers that in addition contain a slip agent.

Accordingly, the present invention relates to a nonwoven fabriccomprising a plurality of polypropylene-containing fibers that form anonwoven web, which fibers in addition contain a slip agent, the web hasa side which is provided with an alternating pattern which consists ofindividualized bonded areas which are in the form of rods which arearranged in the cross direction of the web, the alternating pattern ofindividualized bonded areas defines a non-bonded area, the web has abasis weight in the range of from 5-25 g/m², the surface of the bondedareas is in the range of 5-20% of the total surface of the side, and thesurface of the non-bonded area is in the range of 80-95% of the totalsurface of the side.

A major advantage of the present invention resides in the fact thatnonwoven fabric is relatively simple to make and that is displays asurprisingly high perceived softness. An additional major advantage isthe fact that the present nonwoven fabrics display a surprisingly highperceived softness and at the same time a high tensile strength. This issurprising since it is generally acknowledged that softness anddimensional stability (i.e. high tensile strength) of a thermobondednonwoven fabric are features that mutually exclude each other.

DETAILED DESCRIPTION OF THE INVENTION

In accordance with the present invention the nonwoven fabric comprises aplurality of polypropylene-containing fibers that form a nonwoven webwhich comprises a side which is provided with an alternating patternwhich consists of individualized bonded areas which are in the form ofrods which are arranged in the cross direction of the web. Thealternating pattern which consists of individualized bonded areasdefines a second pattern of non-bonded areas, and the web has a basisweight in the range of from 5-25 g/cm², the surface of the bonded areasis in the range of 5-20% of the total surface of the side, and surfaceof the non-bonded area is in the range of from 80-95% of the totalsurface of the side. The combination of the particular alternatingpattern which consists of individualized bonded areas,polypropylene-containing fibers that in addition contain a slip agentand the high surface of the non-bonded area to be used according to thepresent invention provides the surprisingly high softness. Moreover, thelarge non-bonded areas allow for the fiber to bulk up and increase thebulkiness of the fabric. This is perceived as an even higher softnessfrom both visual and the tactile perspective. Preferably, the surface ofthe non-bonded area is in the range of from 85-92% of the total surfacearea of the side. More preferably, the surface of the non-bonded area isin the range of from 88-91% of the total surface area of the side. Thealternating pattern consists of the individualized bonded areas whichare in the form of rods. Hence, the alternating pattern does not containadditional bonded areas in addition to the rods which are arranged inthe cross direction of the web.

The surface of the bonded areas is preferably in the range of from 8-15%of the total surface area of the side, more preferably in the range offrom 9-12% of the total surface area of the side.

The individualized bonded areas are in the form of rods which arearranged in the cross direction of the web. The cross direction is thedirection along the web material substantially perpendicular to thedirection of forward travel of the web material through themanufacturing line in which the web material is manufactured.

Preferably, the individualized bonded areas in the form of rods each intheir length direction form an angle of 90° with the machine directionof the web.

The rods are preferably arranged in such a way that in the machinedirection no uninterrupted regions exist along the web, while in thecross direction the arrangement of the rods define a plurality ofuninterrupted regions that extend continuously along the web. Such apreferred arrangement of the rods results in a number of improved fabricproperties.

The tensile strength into the cross direction is significantly improved,as the filaments are boldly bound perpendicular to their preferredlay-down direction. It is thereby of importance that no uninterruptedregions in the preferred lay-down direction (i.e. the machine direction)exist, as this would create weak areas of unbonded filaments, resultingin a reduced tensile strength. Moreover, since there are nouninterrupted regions in the machine direction along the web, the freefiber length (i.e. average length of a single fiber between its firstand second bond) is comparatively short, resulting in an improvedabrasion resistance. Further, this particular arrangement of rodsprovides uninterrupted unbonded areas in the cross direction,significantly reducing the bending forces of the fabric and translatinginto an excellent drapability without sacrificing mechanical strength.This finding is surprising because these two properties usually excludeeach other.

The width of these uninterrupted regions in the cross direction in thispreferred arrangement of rods is suitably larger than 750 μm, andpreferably the width is in the range of from 1000-2000 μm.

The rods may have flat ends and/or bended ends. Preferably, the bendedends have a circular shape. Preferably, the rods have a linear shape.

Suitably, the individualized bonded areas in the form of rods have asurface in the range of from 0.7-1.5 mm², preferably in the range offrom 0.9-1.3 mm², and more preferably in the range of from 1.1-1.2 mm².

The nonwoven web has a basis weight in the range of from 5-25 g/m²,preferably in the range of from 8-22 g/m², and more preferably in therange of from 10-20 g/m².

The rods suitably have a maximum width in the range of from 0.1-1.2 mm,preferably in the range of from 0.3-0.8 mm, and more preferably in therange of from 0.4-0.6 mm.

The rods suitably have a maximum length in the range of from 1.2-3.5 mm,preferably in the range of from 1.8-3.0 mm, and more preferably in therange of from 2.2-2.6 mm.

Suitably, the individualized bonded areas in the form of rods have alength which is 2-10 times, preferably 2-8 times their width.

The discrete non-bonded area suitably has a depth in the range of from0.1-0.8 mm, preferably in the range of from 0.1-0.6 mm, more preferablyin the range of from 0.15-0.5 mm, and most preferably in the range offrom 0.15-0.4 mm.

Suitably, the distance between each pair of adjacent rods is in therange of from 1.8-3.0 mm, preferably 2.2-2.6 mm in the cross direction

Suitably, distance between each pair of adjacent rods is in the range offrom 2.5-5.0 mm, preferably 3.3-4.2 mm in the machine direction

In this respect it is observed that the machine direction is thedirection along the web material substantially parallel to the directionof forward travel of the web material through the manufacturing line inwhich the web material is manufactured.

In accordance with the present invention use is made ofpolypropylene-containing fibers. The nonwoven fabric may also containfibers made from other thermoplastic polymers such as polyethylene andits copolymers, aliphatic and aromatic polyesters, and combinationsthereof. Further, the nonwoven fabrics may also comprise natural fiberssuch as wood, cotton, or rayon in combination with thermoplastic fibers.The nonwoven web may also be a composite made up of a mixture of two ormore different fibers or a mixture of fibers and particles. Suitably,the polypropylene-containing fibers are present in an amount of at least25 wt %, based on the total amount of fibers in the nonwoven fabric.Preferably, the polypropylene-containing fibers are present in an amountof at least 50 wt %, more preferably at least 75 wt %, based on thetotal amount of fibers in the nonwoven fabric. Most preferably, thenonwoven fabric only contains polypropylene-containing fibers.

The polypropylene-containing fibers may comprise a polypropylenehomopolymer or a polypropylene copolymer. In particularly, thepolypropylene copolymers can attractively be used in the presentinvention. Preferred are polypropylene materials that comprise apropylene-α-olefin copolymer and a propylene homopolymer.

The melt flow rate (MFR) of the polypropylene material to be used in thepresent invention is suitably less than 90 dg/min. The MFR is determinedusing ASTM test method D1238, 2.16 kg. Preferably, the MFR of thepolyolefin material is in the range of from 15-50 dg/min, morepreferably in the range of from 15-35 dg/min.

The polypropylene-containing fibers to be used in accordance with thepresent invention suitably have a tex of less than 2.5 dtex, preferablyless than 2.2 dtex. A tex is metric measure of the weight per unit of afiber. It is numerically equal to the weight in grams of ten kilometer(10000 meters) of the fiber.

Preferably, the fibers are formed from polyethylene, polypropylene,co-polymers of polyethylene and polypropylene, or blends of polyethyleneand polypropylene or blends of polypropylene and polyethylene with theircopolymers. However, such a mixture contains at least 25 wt %,preferably at least 50 wt % polypropylene, based on the total weight ofthe mixture. More preferably, the polypropylene-containing fibers onlycontain a polypropylene material as the thermoplastic component.Suitable examples of polyolefin materials include propylenehomopolymers.

In the case of propylene-based polymers, the polymers may comprisecomonomer-derived units selected from ethylene and C4-C10 α-olefins.

The polypropylene-containing fibers to be used in accordance with thepresent invention in addition contain a slip agent. It is the use of aslip agent in combination with the particular pattern of rod and apolypropylene material which brings about the surprisingly highperceived softness.

The slip agent is suitably added to the polypropylene material duringthe manufacturing process of the fabric, e.g. in form of a masterbatchduring the spinning process.

The slip agent to be used in accordance with the present invention canbe any slip agent which can suitably be used in the manufacturing ofnonwoven fabrics. Suitably, the slip agent is a hydrocarbon compoundthat preferably contains heteroatoms which create one or more functionalgroups, for example, oxygen-containing groups such as hydroxy, alkoxys,carboxy, esters, nitrogen-containing groups such as amines, amides,phosphor-containing functional groups, or silicone-containing functionalgroups. Moreover, also aryl- and functional aryl groups as well as oneor more unsaturated C—C-bonds can suitably be present.

Typical examples of specifically attractive slip agents are for example,polyethylene and polypropylene waxes, primary and secondary amides suchas for instance erucamide and oleamide, and stearyl derivatives.

The slip agent is suitably present in an amount in the range of from0.1-5 wt %, preferably in an amount of 0.5-3 wt %, based on the totalweight of the polypropylene-containing fibers.

Besides additives already contained in the employed polymers, additionof further additives is possible to provide additional properties to thefibers. Suitable further additives include thermal stabilizers, lightstabilizers, waxes, and additives to make the fabrics either hydrophilicor hydrophobic. The addition of filler materials can sometimes also beof advantage. Suitable filler materials include organic and inorganicfiller materials. Suitable examples of inorganic filler materialsinclude minerals such as calcium carbonate, metals such as aluminium andstainless steel. Suitable examples of organic filler materials includesugar-based polymers.

In a particularly attractive embodiment of the present invention, thepolypropylene-containing fibers contain 98 wt % of a Ziegler-Nattapolypropylene, e.g. LyondellBasell's Moplen HP561R, as the polypropylenematerial and 2 wt % of an erucamide-containing slip additive, e.g.Crodamide ER from Croda Polymer Additives.

Various fiber cross-sections are possible. A round fiber cross-sectionis preferred, but also tri- and multilobal shaped fibers can alsoadvantageously be used. Other suitable fiber cross-sections includetriangular, bone-shaped, moon-shaped, hollow-fibers, and ribbon-shapedcross-sections.

The fibers from which the nonwoven webs are made can suitable be singlecomponent or multicomponent fibers such as bicomponent fibers. Suitableexamples of multicomponent fibers include symmetric and eccentriccore/sheath fibers, side-by-side fibers of A/B or A/B/A-structure,segmented pie fibers, island-in-a-sea fibers, and striped fibers.Preferred are bicomponent fibers where the two components are arrangedin a symmetric core-sheath way or in a side-by-side way. Most preferredare core-sheath bicomponent fibers comprising a higher melting compoundand a lower melting compound, for example polyethylene andpolypropylene. In general, for core-sheath fibers, the core comprisesthe component with the higher melting point and the sheath comprises thecomponent with the lower melting point, but it can be advantageous tohave it in the reversed way. In a preferred embodiment, the bicomponentfiber has a core of polypropylene and a sheath of polyethylene. Inpreferred embodiments, the bicomponent fiber comprises from 10% to 90%by weight of the higher melting component in the core and from 90% to10% by weight of the lower melting component in the sheath. Mostpreferably, the bicomponent fiber has from 30% to 70% by weight of thehigher melting component in the core. The bicomponent fibers may containdifferent types of polypropylene. More preferably, the bicomponent fiberhas a core of a polypropylene which has a higher melting point and asheath of a polypropylene which has a lower melting point. In anotherpreferred embodiment, a side-by-side-bicomponent fiber comprises twopolypropylenes that differ in melt temperature or melt flow.

The fibers are suitably joined by bonding to form a coherent webstructure. Suitable bonding techniques include, but are not limited to,chemical bonding and thermal bonding, for example thermal calendering orbonding by a hot gas stream. Also ultrasonic welding is possible.

The nonwoven fabrics in accordance with the present invention may beproduced by any of the known process for making a nonwoven fabric.

The nonwoven fabric may be a single layer or multi-layer nonwoven fabrichaving, for example, at least one layer of a spunbonded web joined to atleast one layer of a meltblown web, a carded web, or other suitablematerial. Suitably, the nonwoven fabric according to the presentinvention comprises in addition a second nonwoven web.

The nonwoven webs may be extensible, elastic, or non-elastic. Thenonwoven webs may be spunbonded webs, meltblown webs, air-laid webs, orcarded webs. If the nonwoven web is a web of meltblown fibers, it mayinclude meltblown microfibers.

The fibers can be made according to spinning technologies known in theart. Most conveniently employed are spunbond and meltblown processes,from which the nonwoven fabrics can directly be formed.

Spunbond fibers are generally produced by extruding a molten polymerthrough a large spinneret having several thousand holes per linear meteror from banks of smaller spinnerets, for example, containing as few as40 holes. After exiting the spinneret, the molten fibers are quenched bya cross-flow air quench system, then pulled away from the spinneret andattenuated by high speed air. Lay-down of the filaments to create anonwoven layer occurs on a permeable transport belt. Spunbond fibers aregenerally continuous and range in fiber diameter between ca. 10-100 μm.

Meltblown fibers on the other hand are generally much smaller indiameter and usually range between 0.5-10 μm. Additionally, meltblownfibers are considered to be mainly discontinuous.

A meltblowing process is a process in which fibers are formed byextruding a molten thermoplastic material through a plurality of fine,usually circular, die capillaries as molten threads or filaments into ahigh velocity, usually heated, gas streams which attenuate the filamentsof molten thermoplastic material to reduce their diameter. The meltblownprocess normally has the filaments in single row of filaments across thewidth of the die. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface toform a web of randomly dispersed meltblown fibers. Meltblown fibers aremicrofibers which may be continuous or discontinuous.

The nonwoven fabric in accordance with the invention can additionally betreated to add specific properties. Most common are topical treatmentsto make the fabric either hydrophilic or to make it hydrophobic. Mostcommon is the treatment of the fabric with either hydrophilicsurfactants or with a silicon material. In the context of the presentinvention a surface of a nonwoven fabric or nonwoven web is“hydrophilic” when the contact angle of water disposed on that surfaceis less than about 90 and a surface is “hydrophobic” when the contactangle of water disposed on that surface is greater than or equal to 90.

The nonwoven fabric according to the invention can consist of only onetype of fibers or fiber layers, e.g. a spunbond layer, but it suitablycan comprise additional nonwoven layers which may differ from eachother. Suitable multi-layer fabrics may include one or more spunbondlayers (S) and meltblown layers (M), such as SMS, SMMS, SSMMS, etc.adhered to a nonwoven fabric according to the present invention.Usually, these multilayer fabrics are made in one step on a single linewith multiple beams, which generally encompass a combination of spunbondand meltblown beams. In some cases it might be advantageous ortechnically necessary to make a multiple layer according to theinvention in two or more separate steps.

The use of spunbond layers that differ in their fiber cross-section orin their fiber type are possible. Thus, it is also possible to combine alayer of trilobal filaments with a layer of round fibers, or to combinea core-sheath bicomponent layer with a side-by-side biocomponent layer.

In case the nonwoven fabric contains an additional nonwoven web, theadditional may have a basis weight in the range between 5-80 grams/m²,preferably in the range of from 6-50 grams/m².

The nonwoven fabric in accordance with the present invention cansuitably be used in absorbent articles such as disposable absorbentarticles selected from the group consisting of hygiene articles,incontinence articles, diapers, wipes and fem-care articles. Suitabledisposable absorbent articles in which the present nonwoven can be usedinclude those selected from the group consisting of baby diapers,pull-ups, training pants, hygiene closure systems, adult incontinencebriefs and diapers, panty liners, sanitary napkins, medical garments,and bandages. Suitable wipes can comprise wet and dry wipes for hygieneand home care, cleaning wipes, industrial wipes, oil absorbing wipes,and the like.

Disposable absorbent articles are absorbent articles which are notintended to be laundered or otherwise restored or reused as absorbentarticles. Generally, such absorbent articles comprise a back sheet, atop sheet and an absorbent core which is arranged between the back sheetand the top sheet. An additional function of the top sheet is to provideskin comfort.

The present invention also relates to a process for forming the presentnonwoven fabric.

Accordingly, the present invention also relates a process for forming anonwoven fabric comprising the steps of:

(a) forming a nonwoven web of polypropylene-containing fibers that inaddition contain a slip agent; and(b) feeding the nonwoven web into a nip defined between oppositelypositioned first and second rolls, whereby at least one of the rolls hasa patterned outer surface to apply a bonding pattern to the firstnonwoven web, whereby the bonding pattern comprises the alternatingpattern which consists of the individualized bonded areas and thenon-bonded area as defined hereinbefore.

Further, the present invention also relates to a process for forming anonwoven fabric according to claim 11 comprising the steps of:

(a) forming a first nonwoven web;(b) forming a second nonwoven web;(c) forming a third nonwoven web;(d) feeding the first nonwoven web, second nonwoven web and the thirdnonwoven web into a nip defined between oppositely positioned first andsecond rolls, whereby at least one of the rolls has a patterned outersurface to apply a bonding pattern to the first nonwoven web, wherebythe bonding pattern comprises the alternating pattern which consists ofbonded areas and the non-bonded area as defined hereinbefore; and(e) bonding the first, second and third nonwoven web together to formthe nonwoven fabric.

Preferably, in these processes the forming of at least one of the threenonwoven webs is carried out by means of a spunbond process or ameltblown process.

The rolls to be used in the processes according to the present inventionare suitably right circular cylinders that can be formed of anysuitable, durable material. Such rolls will be operated in ways known inthe art.

The locations of the oppositely positioned rolls can suitably be variedto form the nip between the rolls. The nip pressure within nip cansuitably be varied depending upon the properties of the one or morenonwoven webs to be processed. The same is true for the necessarytemperature of the calender rolls, which has to be adjusted according tothe required final properties and the kind of fibers to be bonded.

The bonded areas are suitably formed by means of melt-fusing bycontrolling the temperature of at least one of the rolls. Thetemperature of the outer surface of at least one of the rolls can beadjusted by heating or cooling the rolls. The heating and cooling mayaffect the features of the web(s) being processed and the degree ofbonding of single or multiple webs being passed through the nip formedbetween the respective rolls.

One of the rolls to be used will contain a bonding pattern on itsoutermost surface comprising a continuous pattern of land areas defininga plurality of discrete openings, apertures or holes. Each of theopenings in the one or more rolls will form a discrete unbonded area inat least one side of the nonwoven fabric or nonwoven web. The other rollwill suitably have an outer surface which is much smoother than theother roll. Preferably, the outer surface of the other roll will besmooth or flat. The rotational speeds of the respective rolls aresubstantially identical.

Hereafter the invention will be further illustrated by the non-limitingdrawing.

In FIG. 1, a side of a nonwoven fabric is shown having an alternatingpattern of individualized bonded areas in the form of rods in the crossdirection of the web which define a non-bonded area.

EXAMPLES

In order to show the attractiveness of the present invention the tensilestrength and the results of the Handle-O-Meter test of a known nonwovenfabric and a nonwoven fabric in accordance with the present inventionare compared. The tensile strength is the maximum tensile force (PeakForce) a material will sustain before tensile failure, as measured bythe Tensile Strength Measurement Method (WSP 110.4) set forth herein.The Handle-O-Meter test (WSP 90.3) is used to measure softness andstiffness. These tests are well-known standard methods in the non-wovenindustry. The slip agent used in these Examples was CESA slip PPA0050079 (commercially available from Clariant).

In Table 1, the results are shown of a 15 gsm polypropylene spunbondfabric in accordance with the present invention and a known 15 gsmpolypropylene spunbond.

TABLE 1 standard spunbond spunbond fabric; fabric; oval elliptic CD-rodpattern pattern (18.1%) (10.1%) no slip with slip no slip with slipadditive additive additive additive Tensile strength 25 26 26 27 (N/5cm) in MD WSP 110.4 Handle-O-Meter 56 38 27 16 (mN) WSP 90.3

It will be clear from Table 1 that the combination of a CD-rod patternwith a slip agent provides a surprisingly high softness that with knownpatterns cannot be achieved. The lower the value in the handle-o-meter,the lower is the stiffness, and the less force is needed to deform thefabric. This translates into an increasingly softer feeling.

1. A nonwoven fabric comprising a plurality of fibers that form anonwoven web, the web has a side which is provided with an alternatingpattern which consists of individualized bonded areas which are in theform of rod-shaped patterns which are arranged in the cross direction ofthe web, wherein the rods each in their length direction form an angleof 90° with the machine direction of the web, and the rods are arrangedin such a way that in the machine direction of the web no uninterruptedregions exist along the web while in the cross direction of the web thearrangement of the rods defines a plurality of uninterrupted regionsthat extend continuously along the web, the alternating pattern ofindividualized bonded areas defines a non-bonded area.
 2. The nonwovenfabric according to claim 1, wherein the plurality of fibers comprisepolypropylene and a slip agent.
 3. The nonwoven fabric according toclaim 1, wherein the slip agent is a hydrocarbon compound having one ormore functional groups selected from hydroxide, aryls and substitutedaryls, alkoxys, carboxylates, esters, amides, an unsaturated C—C bond,oxygen, nitrogen, carboxyl, a fatty acid derivative, or a compound basedon a silicone-containing compound.
 4. The nonwoven fabric according toclaim 1, wherein the web has a basis weight on the range of from 5-25g/m², the surface of the bonded areas is in the range of 5-20% of thetotal surface of the side, and the surface of the non-bonded area is inthe range of 80-95% of the total surface of the side.
 5. The nonwovenfabric according to claim 1, wherein the rods have a length that is 2 to10 times the width of the rods.
 6. The nonwoven fabric according toclaim 5, wherein the rods have a length that is from 1.2 to 3.5 mm.
 7. Anonwoven fabric comprising a plurality of polypropylene-containingfibers that form a nonwoven web, which fibers in addition contain a slipagent, the web has a side which is provided with an alternating patternwhich consists of individualized bonded areas which are in the form ofrod-shaped patterns which are arranged in the cross direction of theweb, wherein the rods each in their length direction form an angle of90° with the machine direction of the web, and the rods are arranged insuch a way that in the machine direction of the web no uninterruptedregions exist along the web while in the cross direction of the web thearrangement of the rods defines a plurality of uninterrupted regionsthat extend continuously along the web, the alternating pattern ofindividualized bonded areas defines a non-bonded area.
 8. The nonwovenfabric according to claim 7, wherein, the web has a basis weight on therange of from 5-25 g/m² and the surface of the non-bonded area is in therange of 80-95% of the total surface of the side.
 9. The nonwoven fabricaccording to claim 7, wherein a surface of the bonded area is in therange of from 8-15% of a total surface area of the side.
 10. Thenonwoven fabric according to claim 7, wherein a surface of thenon-bonded area is in the range of from 85-92% of a total surface areaof the side.
 11. The nonwoven fabric process according to claim 7,wherein the slip agent is a hydrocarbon compound having one or morefunctional groups selected from hydroxide, aryls and substituted aryls,alkoxys, carboxylates, esters, amides, an unsaturated C—C bond, oxygen,nitrogen, carboxyl, a fatty acid derivative, or a compound based on asilicone-containing compound.
 12. The nonwoven fabric according to claim7, wherein the fibers have a tex of less than 2.5 dtex.
 13. The nonwovenfabric according to claim 7, wherein the cross-section of the fibers isround.
 14. The nonwoven fabric according to claim 7, wherein thenonwoven web has a basic weight of 8-22 g/m².
 15. The nonwoven fabricaccording to claim 7, comprising additional nonwoven webs.
 16. Thenonwoven fabric according to claim 8 comprising one or more spunbondwebs and one or more meltblown webs.
 17. A process for forming anonwoven fabric comprising the steps of: (a) forming a nonwoven web ofpolypropylene-containing fibers that in addition contain a slip agent;and (b) feeding the nonwoven web into a nip defined between oppositelypositioned first and second rolls, whereby at least one of the rolls hasa patterned outer surface to apply a bonding pattern to the firstnonwoven web, whereby the bonding pattern comprises the alternatingpattern which consists of individualized bonded areas which are in theform of rod-shaped patterns arranged in the cross direction of the web,wherein the rods each in their length direction form an angle of 90°with the machine direction of the web, and the rods are arranged in sucha way that in the machine direction of the web no uninterrupted regionsexist along the web while in the cross direction of the web thearrangement of the rods defines a plurality of uninterrupted regionsthat extend continuously along the web, the alternating pattern ofindividualized bonded areas defines a non-bonded area.
 18. A process forforming a nonwoven fabric according to claim 17 comprising the steps of:(a) forming a first nonwoven web; (b) forming a second nonwoven web; (c)forming a third nonwoven web; (d) feeding the first nonwoven web, secondnonwoven web and the third nonwoven web into a nip defined betweenoppositely positioned first and second rolls, whereby at least one ofthe rolls has a patterned outer surface to apply a bonding pattern tothe first nonwoven web, whereby the bonding pattern comprises thealternating pattern which consists of bonded areas and the non-bondedarea as defined in claim 17; and (e) bonding the first, second and thirdnonwoven web together to form the nonwoven fabric.
 19. A processaccording to claim 18, wherein at least one of the three nonwoven websis made by means of a spunbond process or a meltblown process.
 20. Acalender nip for imparting a bonding pattern to a nonwoven web, the nipcomprising two oppositely positioned first and second rolls, whereby atleast one of the rolls has a patterned outer surface to apply a bondingpattern to the first nonwoven web, the outer surface comprising aplurality of alternating rows of raised surfaces that extend in a crossdirection of the roll, each row of raised surfaces consisting ofindividual raised surface having a rod shape that extends in the crossdirection of the roll, wherein the rods each in their length directionform an angle of 90° with the machine direction of the roll, and therods are arranged in such a way that in the machine direction of theroll no uninterrupted regions exist along the roll while in the crossdirection of the web the arrangement of the rods defines a plurality ofuninterrupted regions that extend continuously in the cross direction ofthe roll.
 21. The calender nip of claim 20, wherein the rods have alength that is from 1.2 to 3.5 mm, and said length is 2 to 10 times awidth of the rods.